CAUTION: Incorrect removal or installation of the timing belt can result in damage to internal engine components.
1. Remove battery and under cover. 2. Drain cooling system and disconnect upper radiator hose at engine. 3. Remove cooling fan and shroud and disconnect lower radiator hose at engine. 4. Remove air conditioner compressor, if used. 5. Remove fan belt and crankshaft pulley. 6. Remove timing pulley housing covers. Refer to ``Timing Pulley Housing Covers, Replace'' for procedure.
7. Remove tension spring, Fig. 18, tension pulley nut, Fig. 19, tension center, pulley and timing belt. 8. Disconnect engine control cable and wiring harness from fuel cut-off solenoid. 9. Disconnect fuel hoses and injection pipes. Use a back-up wrench to hold delivery holder when loosening sleeve nuts on injection pump side.10. Install a 6 mm bolt with a pitch of 1.25 into threaded hole in timing pulley to prevent pulley from turning, then remove bolts retaining injection pump timing pulley and remove pulley using suitable puller.
11. Remove injection pump flange retaining nuts and rear bracket bolts, Fig. 33, then remove injection pump.
12. Install injection pump with marks on flange and front bracket aligned, Fig. 27.13. Install injection pump timing pulley and torque bolt to 42-52 ft. lbs. (5.8-7.2 kg-m).
14. Rotate crankshaft until No. 1 piston is at TDC compression stroke, Fig. 7, and marks on timing pulley are aligned, Fig. 20.15. Install timing belt. Refer to ``Timing Belt, Replace'' for procedure.
1. Check that alignment mark on injection pump flange is aligned with alignment mark on injection pump front bracket, Fig. 27.
2. Bring No. 1 cylinder to top dead center compression by turning crankshaft until timing mark on pulley aligns with pointer, Fig. 7.
3. Remove timing pulley housing and check that timing belt is properly tensioned, and that timing marks are aligned, Fig. 23.
4. Disconnect injection pipe from injection pump and remove distributor head screw. Install static timing gauge J-29763, Fig. 28 then set lift to approximately .040 inch (1 mm) from plunger.
5. Bring No. 1 piston to 45-60° before top dead center by turning crankshaft, Fig. 29, then set dial indicator to zero. Turn crankshaft slightly in both directions and check that gauge indication is stable.
6. Turn crankshaft in normal direction of rotation and note reading on dial indicator when the 15° timing mark on pulley is aligned with pointer, Fig. 30. If dial indicator reading is not .020 inch (.5 mm), hold crankshaft at the 15° mark and loosen the two nuts on injection pump flange, Fig. 31. Move pump until reading on dial indicator is .020 inch (.5 mm), then tighten nuts.
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